Field terminable fiber optic connector assembly

ABSTRACT

An assembly includes a connector and a carrier engaged therewith. Connector has a first mating end and a second end and a first fiber. The fiber defines a first end adjacent the mating end and a second end protruding from the connector second end. Carrier has a connector end and an opposite cable end and includes a heat activated meltable portion adjacent the cable end. An alignment structure is on the carrier and includes first and second ends, and a throughhole. The first end of the alignment structure receives the second end of the first fiber and the second end receives an end of a second fiber entering the carrier. The heat activated portion melts and assumes a flowable condition when exposed to a predetermined amount of heat and resolidifies when heat is removed, bonding the second fiber to the carrier after the first and second fibers are aligned.

CROSS REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional PatentApplication Ser. No. 61/182,184, filed May 29, 2009, which applicationis hereby incorporated by reference in its entirety.

TECHNICAL FIELD

The present disclosure relates to a fiber optic connector assembly, andmore particularly, to a field terminable fiber optic connector assembly.

BACKGROUND

The use of fiber optic networks as a signal-carrying medium forcommunications is now widespread and continues to increase. Fiber opticnetworks frequently include a plurality of fiber optic cables havingoptical fibers. As fiber optic networks continue to grow, the need foroptical fiber terminations for maintenance or expansion purposes is alsogrowing. As such, there is a need for an optical fiber termination whichcan be performed in the field.

SUMMARY

An aspect of the present disclosure relates to a fiber optic connectorassembly that includes a connector and a carrier. The connector has afirst mating end and a second end and a first optical fiber terminatedthereto. The fiber defines a first end adjacent the mating end and asecond end protruding from the second end of the connector. A polymericcarrier having a connector end and an oppositely disposed cable end isengaged with the connector. The carrier includes a heat activatedmeltable portion adjacent the cable end. The meltable portion isconfigured to melt and assume a flowable condition. An alignmentstructure is disposed on the carrier that includes a first end, a secondend, and a throughhole. The first end of the alignment structure is forreceiving the second end of the first optical fiber and the second endof the alignment structure is for receiving an end of a second opticalfiber entering the cable end of the carrier. The heat activated portionof the carrier is configured to melt and assume a flowable conditionwhen exposed to a predetermined amount of heat and resolidify when theheat is removed for bonding the second optical fiber to the carrierafter the first fiber is aligned with the second fiber. Thermal energymay be applied to the polymeric carrier to melt the heat activatedportion of the carrier.

According to another aspect of the disclosure, the portion of thepolymeric carrier that is to be melted is positioned such that, whenmelted, the polymeric material contacts at least a portion of the secondoptical fiber entering the cable end of the carrier. After apredetermined time, the heat source is removed allowing the polymericmaterial to solidify. Once the material is solid, the contacted fiber issecured to the carrier. Other parts of the fiber optic connectorassembly such as the alignment structure may also be secured to thecarrier once the melted portions of the carrier solidify.

According to another aspect of the disclosure, the polymeric carrierwith the meltable portion may be utilized in combination with a heatactivated adhesive element for the bonding.

According to yet another aspect of the disclosure, various heat sourcesmay be utilized to provide the thermal energy to the polymeric carrierand/or heat activated adhesive element. The heat sources may includearrangements such as a resistor in contact with a conductive elementthat is in contact with the polymeric carrier and/or the adhesiveelement. The heat sources may also include tools such as a solder ironin direct contact with the conductive element that is in contact withthe polymeric carrier and/or the heat adhesive element.

Another aspect of the disclosure relates to a fiber optic terminationassembly comprising a support structure having a first end and anoppositely disposed second end, the support structure configured toreceive a first optical fiber from the first end and a second opticalfiber from the second end. An alignment structure is disposed on thesupport structure, the alignment structure including a first end and asecond end and a throughhole extending from the first end to the secondend, the alignment structure including a cutaway portion extendinggenerally perpendicularly to and communicating with the throughhole. Thefirst optical fiber enters the alignment structure from the first endand is positioned within at least a portion of the throughhole with anend of the first optical fiber being located within the cutaway portionof the alignment structure. The second optical fiber enters thealignment structure from the second end and is positioned within atleast a portion of the throughhole with an end of the second opticalfiber being located within the cutaway portion of the alignmentstructure. A window is disposed within the cutaway portion of thealignment structure over the ends of the first and second optic fibers,the window configured for visually inspecting an alignment of the end ofthe first optical fiber with the end of the second optical fiber. Afirst thermally conductive element is positioned between the first endof the support structure and the alignment structure and a secondthermally conductive element is positioned between the second end of thesupport structure and the alignment structure, the first thermallyconductive element configured to transfer heat for melting a heatactivated element to bond the first optical fiber to the supportstructure and the second thermally conductive element configured totransfer heat for melting a heat activated element to bond the secondoptical fiber to the support structure.

A variety of additional inventive aspects will be set forth in thedescription that follows. The inventive aspects can relate to individualfeatures and to combinations of features. It is to be understood thatboth the forgoing general description and the following detaileddescription are exemplary and explanatory only and are not restrictiveof the broad inventive concepts upon which the embodiments disclosedherein are based.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings are included to provide a furtherunderstanding of the inventive aspects of the present disclosure and areincorporated in and constitute a part of this specification. Thedrawings illustrate exemplary embodiments of the present disclosure andtogether with the description serve to further explain the principles ofthe disclosure. Other aspects of the present disclosure and many of theadvantages of the present disclosure will be readily appreciated as thepresent disclosure becomes better understood by reference to thefollowing Detailed Description when considered in connection with theaccompanying drawings, and wherein:

FIG. 1 is a perspective view of a fiber optic connector assembly havingfeatures that are examples of inventive aspects in accordance with theprinciples of the present disclosure, the fiber optic connector assemblyshown in a fully assembled configuration;

FIG. 1A illustrates the fiber optic connector assembly of FIG. 1 withthe alignment guide of the assembly removed;

FIG. 2 is a fully exploded view of the fiber optic connector assembly ofFIG. 1;

FIG. 2A illustrates the exploded view of the fiber optic connectorassembly of FIG. 1A;

FIG. 3 is a front perspective view of a fiber optic connector of thefiber connector assembly of FIG. 1;

FIG. 4 is a rear perspective view of the fiber optic connector of FIG.3;

FIG. 5 is a perspective view of the saddle assembly of the fiber opticconnector assembly of FIG. 1;

FIG. 6 is an exploded view of the saddle assembly of FIG. 5;

FIG. 7 is an exploded view of the alignment guide of the fiber opticconnector assembly of FIG. 1;

FIG. 8 is a cross-sectional view of the alignment guide taken along line8-8 of FIG. 7 with the window of the alignment guide inserted into thebase of the alignment guide;

FIG. 9 is a front view of the alignment guide of FIG. 7;

FIG. 10 is a cross-sectional view of the alignment guide taken alongline 10-10 of FIG. 7 with the window of the alignment guide insertedinto the base of the alignment guide;

FIG. 11 is a perspective view of the base of the alignment guide of FIG.7;

FIG. 12 is a side view of the base of FIG. 11;

FIG. 13 is a top view of the base of FIG. 11;

FIG. 14 is a cross-sectional view of the base taken along line 14-14 ofFIG. 13;

FIG. 15 is a rear view of the base of FIG. 11;

FIG. 16 is a cross-sectional view of the base taken along line 16-16 ofFIG. 12;

FIG. 17 is a perspective view of the alignment window of the alignmentguide of FIG. 7;

FIG. 18 is a front view of the alignment window of FIG. 17;

FIG. 19 is a right side view of the alignment window of FIG. 17;

FIG. 20 is an exploded front perspective view of a second embodiment ofa fiber optic connector assembly having features that are examples ofinventive aspects in accordance with the principles of the presentdisclosure;

FIG. 21 is an exploded rear perspective view of the fiber opticconnector assembly of FIG. 20;

FIG. 22 is a right side view of the fiber optic connector assembly ofFIG. 20, the fiber optic connector assembly shown in a fully assembledconfiguration;

FIG. 23 is a top view of the fiber optic connector assembly of FIG. 22;

FIG. 24 is a cross-sectional view of the fiber optic connector assemblytaken along line 24-24 of FIG. 23;

FIG. 25 is an exploded front perspective view of a third embodiment of afiber optic connector assembly having features that are examples ofinventive aspects in accordance with the principles of the presentdisclosure;

FIG. 26 is an exploded rear perspective view of the fiber opticconnector assembly of FIG. 25;

FIG. 27 is a right side view of the fiber optic connector assembly ofFIG. 25, the fiber optic connector assembly shown in a fully assembledconfiguration;

FIG. 28 is a top view of the fiber optic connector assembly of FIG. 27;

FIG. 29 is a cross-sectional view of the fiber optic connector assemblytaken along line 29-29 of FIG. 28;

FIG. 30 is an exploded front perspective view of a fourth embodiment ofa fiber optic connector assembly having features that are examples ofinventive aspects in accordance with the principles of the presentdisclosure;

FIG. 31 is an exploded rear perspective view of the fiber opticconnector assembly of FIG. 30;

FIG. 32 is a right side view of the fiber optic connector assembly ofFIG. 30, the fiber optic connector assembly shown in a fully assembledconfiguration;

FIG. 33 is a top view of the fiber optic connector assembly of FIG. 32;

FIG. 34 is a cross-sectional view of the fiber optic connector assemblytaken along line 34-34 of FIG. 33;

FIG. 35 is an exploded front perspective view of a fifth embodiment of afiber optic connector assembly having features that are examples ofinventive aspects in accordance with the principles of the presentdisclosure;

FIG. 36 is an exploded rear perspective view of the fiber opticconnector assembly of FIG. 35;

FIG. 37 is a right side view of the fiber optic connector assembly ofFIG. 35, the fiber optic connector assembly shown in a fully assembledconfiguration;

FIG. 38 is a top view of the fiber optic connector assembly of FIG. 37;

FIG. 39 is a cross-sectional view of the fiber optic connector assemblytaken along line 39-39 of FIG. 38;

FIG. 40 is a front perspective view of a carrier that is configured foruse with each of the fiber connector assemblies shown in FIGS. 20-39;

FIG. 41 is a rear perspective view of the carrier of FIG. 40;

FIG. 42 is a right side view of the carrier of FIG. 40;

FIG. 43 is a left side view of the carrier of FIG. 40;

FIG. 44 is an exploded perspective view of a termination assembly havingfeatures that are examples of inventive aspects in accordance with theprinciples of the present disclosure;

FIG. 45 illustrates the termination assembly of FIG. 44 in a fullyassembled configuration;

FIG. 46 is a side view of the termination assembly of FIG. 45;

FIG. 47 is a top view of the termination assembly of FIG. 45;

FIG. 48 is a cross-sectional view of the termination assembly takenalong line 48-48 of FIG. 47;

FIG. 49 is an exploded perspective view of another embodiment of atermination assembly having features that are examples of inventiveaspects in accordance with the principles of the present disclosure;

FIG. 50 illustrates the termination assembly of FIG. 49 in a fullyassembled configuration;

FIG. 51 is a side view of the termination assembly of FIG. 50;

FIG. 52 is a top view of the termination assembly of FIG. 50;

FIG. 53 is a cross-sectional view of the termination assembly takenalong line 53-53 of FIG. 52;

FIG. 54 is an exploded perspective view of another embodiment of atermination assembly having features that are examples of inventiveaspects in accordance with the principles of the present disclosure;

FIG. 55 illustrates the termination assembly of FIG. 54 in a fullyassembled configuration;

FIG. 56 is a side view of the termination assembly of FIG. 55;

FIG. 57 is a top view of the termination assembly of FIG. 55;

FIG. 58 is a cross-sectional view of the termination assembly takenalong line 58-58 of FIG. 57;

FIG. 59 is an exploded perspective view of yet another embodiment of atermination assembly having features that are examples of inventiveaspects in accordance with the principles of the present disclosure;

FIG. 60 illustrates the termination assembly of FIG. 59 in a fullyassembled configuration;

FIG. 61 is a side view of the termination assembly of FIG. 60;

FIG. 62 is a top view of the termination assembly of FIG. 60;

FIG. 63 is a cross-sectional view of the termination assembly takenalong line 63-63 of FIG. 62;

FIG. 64 is a perspective view of a carrier configured for use with eachof the termination assemblies shown in FIGS. 44-63;

FIG. 65 is a side view of the carrier of FIG. 64;

FIG. 66 is a perspective view of another embodiment of a carrierconfigured for use with a termination assembly for bonding a firstoptical fiber to another optical fiber, wherein neither of the opticalfibers are terminated to a fiber optic connector;

FIG. 67 is a side view of the carrier of FIG. 66;

FIG. 68 is a perspective view of a base of an alignment guide configuredfor use with a termination assembly for bonding a first optical fiber toanother optical fiber, wherein neither of the optical fibers areterminated to a fiber optic connector, such as those shown in FIGS.44-67;

FIG. 69 is a side view of the base of FIG. 68;

FIG. 70 is a top view of the base of FIG. 68;

FIG. 71 is a front view of the base of FIG. 68;

FIG. 72 is a cross-sectional view of the base taken along line 72-72 ofFIG. 70; and

FIG. 73 is a cross-sectional view of the base taken along line 73-73 ofFIG. 69.

DETAILED DESCRIPTION

Reference will now be made in detail to the exemplary aspects of thepresent disclosure that are illustrated in the accompanying drawings.Wherever possible, the same reference numbers will be used throughoutthe drawings to refer to the same or like parts.

Referring now to FIGS. 1 and 2, a fiber optic connector assembly 10 thatcan be used in terminating at least one optical fiber in the field isshown. In the embodiment shown, the fiber optic connector assembly 10includes two simplex assemblies 10 a joined together to form a duplexassembly 10 b. Each simplex assembly 10 a generally includes a carrier12 and a fiber optic connector 14 that is coupled to the carrier 12. Thesimplex assemblies 10 a may be joined together with at least oneremovable joint pin 16 that is coupled to the connectors 14 of theassemblies 10 a. Also, the each of the carriers 12 of the fiber opticconnector assemblies 10 a includes a hole 18 on a first side 20 and anintegrally molded pin 22 on an opposing second side 24 so that twocarriers 12 may be joined together. Since each carrier 12 includes ahole 18 and a molded pin 22 on opposite, alternating sides, a carrier 12can be joined to another carrier at either side thereof.

The separability of the fiber optic connector assemblies 10 a providesthe advantage of using one or two assemblies, as needed, or being ableto swap the assemblies when the position of the two fiber opticconnectors 14 have to be switched relative to one another. For example,the position of the two fiber optic connectors 14 may have to beswitched when the fiber optic connector assembly 10 of the presentdisclosure is used as an insert within a housing such as the housing ofa hybrid fiber/copper connector or a quad connector as described in U.S.patent application entitled “HYBRID FIBER/COPPER CONNECTOR SYSTEM ANDMETHOD”, filed Nov. 26, 2008, having Ser. No. 12/323,980, the entiredisclosure of which is incorporated herein by reference.

As discussed in the above-mentioned application that has beenincorporated herein by reference, if the gender of one of the hybridconnectors or quad connectors needs to be changed, the position of thetwo fiber optic connectors 14 within the housing may need to beswitched. This can be accomplished by separating the two simplex fiberoptic connector assemblies 10 a of the present disclosure and swappingtheir positions.

Although described in U.S. patent application entitled “HYBRIDFIBER/COPPER CONNECTOR SYSTEM AND METHOD”, filed Nov. 26, 2008, havingSer. No. 12/323,980 as being usable in hybrid or quad connectorhousings, the fiber optic connector assembly 10 of the presentdisclosure can be used as an insert in any type of housing to protectthe fiber optic connector assembly from damage.

While the connectors 14 shown and described as being used with the fiberoptic connector assembly 10 of the present disclosure are either LX.5 orBX5 connectors as manufactured by ADC Telecommunications, Inc., whichhave been described in detail in U.S. Pat. Nos. 5,883,995 and 6,142,676and U.S. patent application entitled “HYBRID FIBER/COPPER CONNECTORSYSTEM AND METHOD”, filed Nov. 26, 2008, having Ser. No. 12/323,980,hereby incorporated by reference in their entirety, it will beunderstood by those skilled in the art that the scope of the presentdisclosure is not limited to the use of a LX.5 or BX5-type connectorwithin the assembly. Also, while the fiber optic connector assembly 10of the present disclosure is depicted and described as being formed fromtwo simplex connector assemblies 10 a joined together to form a duplexassembly 10 b, in other embodiments, the fiber optic connector assembly10 can be configured to include any number of connectors 14 and able toterminate any number of optical fibers. Also, while the fiber opticconnector assembly 10 of the present disclosure includes simplexassemblies 10 a that are removably joined together, in otherembodiments, the fiber optic connector assembly 10 may include anynumber of assemblies that are integrally formed.

For sake of simplicity, the fiber optic connector assembly 10 of thepresent disclosure will be described with respect to one of the simplexassemblies 10 a, with the understanding that the description thereofwill be applicable to the other of the simplex assemblies 10 a.

Still referring to FIGS. 1 and 2, the fiber optic connector assembly 10,in addition to the carrier 12 and the fiber optic connector 14, alsoincludes a saddle assembly 26 and an alignment guide 28 that are coupledto the carrier 12. As will be described in further detail below, thealignment guide 28 is used to align a factory terminated optical fiber30 with a field optical fiber 32 and the saddle assembly 26 is used tomechanically splice the factory fiber 30 to the field fiber 32.

The carrier 12 includes a connector end 34 and a cable end 36, which isoppositely disposed from the connector end 34. In the presentembodiment, the connector end 34 defines a slot 38 for slidably mountingthe connector 14. The connector 14, further details of which aredescribed in U.S. Pat. Nos. 5,883,995 and 6,142,676 and U.S. patentapplication Ser. No. 11/735,267, incorporated herein by reference intheir entirety, defines a tube 40 adjacent the rear end 42 of theconnector 14. The tube 40 defines an annular groove 44 (see FIG. 4)disposed on the outer surface of the tube 40. The connector 14 is placedon the carrier 12 with the annular groove 44 slidably fitting in theslot 38 of the carrier 12. Once slidably inserted, the connector 14 maybe epoxied to the carrier 12. It will be understood by those skilled inthe art that the scope of the present disclosure is not limited to thecarrier defining a slot for mounting the connector and that theconnector can be mounted to the carrier in any other suitable manner.

Still referring to FIGS. 1 and 2, disposed between the connector end 34and the cable end 36 of the carrier 12 is a fiber support 48. In theembodiment shown, the fiber support 48 defines a V-shaped guide way 50that narrow as the depth of the guide way 50 increases.

A termination region, generally designated by 52, is disposed betweenthe cable end 36 of the carrier 12 and the fiber support 48. Thetermination region 52 is the portion of the carrier 12 wherein a factoryterminated fiber 30 that extends from the connector 14 is mechanicallyspliced to a field fiber 32 that is aligned with the factory fiber 30.

The termination region 52 of the carrier 12 defines a groove 54 forsupporting the alignment guide 28. The groove 54 is contoured to fit theouter surface of the alignment guide 28. The termination region 52 alsodefines a guide path 56 that extends from the rear end of the alignmentguide 28 (when the alignment guide is in place) to the cable end 36 ofthe carrier 12. The guide path 56 is configured to generally align witha crimp tube hole 60 defined at the cable end 36 of the carrier 12 andalso align with the guide way 50 of the fiber support 48 of the carrier12. As will be described in further detail below, when the alignmentguide 28 is positioned within the carrier 12, the guide path 56 alsoaligns with the throughhole 104 of the alignment guide 28 so that afactory terminated fiber 30 can be matched up to the field fiber 32.

Adjacent the cable end 36 of the carrier 12, each of the right and leftsidewalls 64, 66 of the carrier 12 defines a vertical recess 68. Thevertical recesses 68 are configured to accommodate the legs 70 of thesaddle 72 when the saddle 72 is placed on the carrier 12, as will bediscussed in further detail below. Although in the present disclosure,each carrier 12 is shown to include its own individual saddle 72, inother embodiments, a single, larger saddle may be used to expand thewidth of two or more simplex carriers 12.

The carrier 12 further include a crimp tube 74, which is engaged withthe cable end 36 of the carrier 12. In the present embodiment, the crimptube 74 is in a press-fit engagement with the crimp tube hole 60 in thecable end 36 of the carrier 12. In other embodiments, the crimp tube 74may be molded integrally with the carrier 12. The crimp tube 74 definesa passageway through which the cleaved field optical fiber 32 isinserted. Strength members/layers (e.g., Kevlar) of a fiber optic cablecan be crimped on the outer surface of the crimp tube 74 for securingthe fiber optic cable to the carrier 12.

Referring now to FIGS. 5 and 6, the saddle assembly 26 is shown incloser detail. The saddle assembly 26 includes the saddle 72 and aresistor 80 with a heat responsive adhesive element 82 configured to bepositioned between the saddle 72 and the carrier 12. In the embodimentshown, the heat responsive element 82 is a glue pellet 83. Although inthe depicted embodiment, glue pellet 83 is shown as being generallyrectangular, it will be understood by those skilled in the art thatother shapes for the glue pellet 83 may be used. The glue pellet 83includes a first surface 84 and an oppositely disposed second surface86. In the depicted embodiment, at least one pathway 88 is pre-formed inthe glue pellet 83. In the depicted embodiment, the at least one pathway88 is a channel 89 that is pre-formed in the second surface 86 of theglue pellet 83. The channel 89 is adapted to receive a portion of thecleaved field optical fiber 32 and a portion of the field buffer, whichsurrounds the cleaved field optical fiber 32. In the present embodiment,the channel 89 is accurately shaped so as to conform to the outersurface of the buffer. It should be noted that the shape of the gluepellet 83 may be varied in other embodiments and may or may not includea preformed channel, depending upon the application.

As shown in FIG. 5, the glue pellet 83 is in thermally conductivecontact with the saddle 72, which is in thermally conductive contactwith the resistor 80. Thus, the saddle 72 is preferably made out ofthermally conductive materials. In the present embodiment, the firstsurface 84 of the glue pellet 83 is in contact with a bottom surface 90of the saddle 72, thereby establishing the thermally conductive contactbetween the glue pellet 83 and the saddle 72. The resistor 80 is incontact with a top surface 92 of the saddle 72, thereby establishing thethermally conductive contact between the resistor 80 and the saddle 72.Similar saddle assemblies including shaped adhesive pre-forms aredescribed in U.S. patent application Ser. Nos. 11/735,267 and11/735,260, the disclosures of which are incorporated herein byreference in their entirety.

When the field optical fiber 32 is ready for termination, a portion ofthe outer surface of the buffer of the field fiber optic cable isdisposed in the channel 89 of the glue pellet 83. In the presentembodiment, the glue pellet 83 is shaped such that nearly half of theouter circumference of the outer surface of the buffer is disposed inthe channel 89.

Still referring to FIGS. 5 and 6, the saddle 72 is generally U-shapedwith two legs 70 extending vertically downwardly. The glue pellet 83 isreceived between the legs 70. The legs 70 are configured to slide withinthe recesses 68 defined on the sidewalls 64, 66 of the carrier 12. Aswill be described in further detail below, when the glue pellet 83melts, the saddle 72 moves vertically downwardly with respect to thecarrier 12 with the legs 70 riding along the recesses 68.

Referring now to FIGS. 7-19, the alignment guide 28 in the fiber opticconnector assembly 10 serves as the location for the termination of theoptical fibers. The alignment guide 28 includes a base 100 and analignment window 102 that is separately mounted on the base 100.

The base 100 is generally cylindrical in shape. In other embodiments,other shapes may be used for the base 100. The base 100 defines athroughhole 104 extending from a first end 106 to the second end 108. Asshown in the Figures, at each end, the base defines a conical portion110. The conical portions 110 taper from a larger diameter portionadjacent the ends toward a small diameter portion toward the center ofthe base 100. The conical portions 110 are configured to facilitateinsertion of the optical fibers into the base 100.

The alignment guide 28 includes a cutout portion 112 about halfway alongthe length of the base 100. As will be discussed in further detailbelow, the cutout 112 accommodates the window 102 that is placed on thebase 100. The cutout 112 is configured to expose and communicate withthe throughhole 104 extending from the first end 106 to the second end108 of the base 100.

The base 100 also includes a cutaway region 114 adjacent the second end108. The cutaway region 114 is configured to accommodate a portion ofthe saddle 72 when the glue pellet 83 melts and the saddle 72 movesvertically downwardly. When the saddle 72 comes to rest, the bottomsurface 90 of the saddle 72 may rest on the cutaway region 114 of thebase 100.

When the base 100 is initially provided on the fiber optic connectorassembly 10, a factory fiber 30 that is terminated to the connector 14extends through the throughhole 104 in the base 100 about halfwaythrough the length of the base 100. The conical portion 110 at the firstend 106 of the base 100 facilitates initial insertion of the factoryfiber 30 into the base 100 of the alignment guide 28. The end of thefactory fiber 30 is exposed to the cutout portion 112 of the base 100.

The fiber that is factory terminated to the connector 14 and extendinghalfway through the length of the base 100 is supported by the fibersupport 48 of the carrier 12 when the connector 14 and the base 100 areplaced on the carrier 12.

Referring to FIGS. 17-19, the window 102 of the alignment guide 28 isshown in closer detail. The window 102 is placed within the cutoutportion 112 of the base 100 and may be epoxied to the base 100. Thewindow 102 is preferably made out of a transparent material such aspyrex. Other materials are possible. The window 102 is configured toallow visual confirmation of the alignment between the factory fiber 30that extends about halfway into the base 100 (exposed to the cutout 112)and the field fiber 32 that will be inserted from the opposite end ofthe carrier 12 into the base 100.

The window 102 defines a box-like configuration with a cutout portion120 at the bottom 122. As shown in FIG. 10, when the window 102 isplaced within the cutout 112 of the base 100, the cutout portion 120 ofthe window 102 is exposed toward one side of the base 100 with a portionof the cutout 120 also lying over the factory fiber/field fiberalignment location. The cutout portion 120 of the window 102 isconfigured to allow any excess index matching gel to flow thereinto.

Once the factory fiber side of the fiber optic termination assembly iscorrectly positioned, the connector 14, the factory fiber stub 30 andthe alignment guide 28 may be epoxied in place on the carrier 12.

In use, with the connector 14 engaged to the carrier 12, the opticalfiber 30 affixed in the guide way 50 of the fiber support 48, and thefactory fiber end inserted into the throughhole 104 of the base 100 ofthe alignment guide 28, an end of the cleaved field optical fiber 32 isinserted into the passageway of the crimp tube 74 defined at the rear ofthe carrier 12. The end of the cleaved field optical fiber 32 isinserted through the channel 89 of the glue pellet 83 and into thethroughhole 104 of the base 100 of the alignment guide 28. In thepresent embodiment, an index matching gel is disposed between thecleaved end of the cleaved field optical fiber 32 and the end of thefactory optical fiber 30. The index matching gel has an index ofrefraction that matches the index of refraction of the glass of thefactory optical fiber 30 and the cleaved field optical fiber 32.According to one embodiment, the index matching gel may be hydroscopic.When the fiber ends are pushed together, the index matching gel flowsinto the cutout portion 120 of the window 102 filling at least a portionof the cutout 120.

With the cleaved end of the cleaved field optical fiber 32 inserted intothe alignment guide 28, optical radiation is passed through the opticalfibers to assess proper alignment of the fiber end of the factory fiber30 and the cleaved end of the field fiber 32. As viewed from the window102, if optical radiation is detectable at the junction, then thealignment/abutment is not correct. The cleaved end may have to bepolished or cleaned and reinserted into the alignment guide 28. Iflittle to no radiation is detectable at the junction of the factoryfiber end and the cleaved field fiber end, then the cleaved fieldoptical fiber 32 and the buffer can be secured to the fiber opticconnector assembly 10 using the saddle assembly 26.

To secure the cleaved optical fiber 32 and the buffer to the fiber opticconnector assembly 10, an electrical power source is connected to theresistor 80. Electrical current is passed through the resistor 80 whichheats up the glue pellet 83 by way of the thermally conducting saddle72. As the glue pellet 83 heats up, the glue pellet 83 becomes tacky andadheres to the buffer and the cleaved optical fiber 32 and closes thepassageway of the crimp tube 74. When the current is interrupted, theglue pellet 83 resets to secure the buffer and the cleaved optical fiber32 in its correct position in alignment with the factory optical fiber30.

When the glue pellet 83 first starts to melt, the legs 70 of the saddle72 slide vertically downwardly along the recesses 68 defined on thesidewalls 64, 66 of the carrier 12. As discussed previously, the cutawayregion 114 of the base 100 is configured to accommodate at least aportion of the saddle 72 as the saddle 72 moves downwardly relative tothe carrier 12. When the glue pellet 83 resets, the buffer of the fieldfiber 32 is sealed to the guide path 56 of the carrier terminationregion 52, the rear end of the base 100 of the alignment guide 28 issealed to the groove 54 in the carrier 12, and the field fiber 32 issealed to the base 100 of the alignment guide 28, securing the entirerear side of the fiber optic termination assembly 10 in correctalignment.

A field termination kit as described in further detail in U.S. patentapplication entitled “FIELD TERMINATION KIT”, filed Apr. 11, 2008,having Ser. No. 12/101,366, the entire disclosure of which isincorporated herein by reference, can be used in terminating the fieldfiber to the factory fiber as discussed herein.

In one embodiment, the glue pellet 83 may be remeltable such that if theperformed seal is not satisfactory, the glue pellet 83 can be remeltedby the application of electric current and reset.

In one embodiment, the carrier 12 may be manufactured out of adielectric or polymeric material such that substantially all of the heatenergy from the resistor 80 is transferred to the conductive saddle 72rather than the carrier itself. In other embodiments, the carrier 12 maybe made out of metallic materials.

In other embodiments of the carrier 12 and the saddle 72 of the fiberoptic connector assembly, the legs 70 of the saddle 72 may includeinwardly extending tab portions at the ends of the legs 70 for securingthe saddle 72 to the carrier 12 and to limit separation during upwardmovement of the saddle 72 relative to the carrier 12. In such anembodiment, the saddle 72 would snap fit onto the carrier 12 with thelegs 70 extending along the recesses 68 and the inwardly extending tabportions extending into inwardly extending slots formed at the ends ofthe recesses 68. In this manner, the saddle 72 may remain attached tothe carrier 12 even if the saddle 72 moves upwardly relative to thecarrier 12, with the tabs of the legs 70 catching the inwardly extendingslots at the bottom ends of the recesses 68 of the carrier 12.

As discussed above, with the field optical fiber 32 secured, the fiberoptic connector assembly 10 can also be provided as an insert for ahousing to protect the fiber optic connector assembly 10 from damage. Anumber of housings into which the fiber optic connector assembly 10 canbe inserted are described in U.S. patent application entitled “HYBRIDFIBER/COPPER CONNECTOR SYSTEM AND METHOD”, filed Nov. 26, 2008, havingSer. No. 12/323,980, hereby incorporated by reference in its entirety.

Referring now to FIGS. 20-24, a second embodiment of a fiber opticconnector assembly 210 that can be used in terminating at least oneoptical fiber in the field is shown. The fiber optic connector assembly210 is similar in construction and use to the fiber optic connectorassembly 10 shown in FIGS. 1-19 of the present disclosure, except for anumber of differences that will be highlighted in further detail below.

For sake of simplicity, the fiber optic connector assembly 210 will bedescribed with respect to a simplex assembly. This is with theunderstanding that, as in the first embodiment of the fiber opticconnector assembly 10 shown in FIGS. 1-19, the simplex fiber opticconnector assembly 210 may be joined to other like simplex assemblies toform a duplex or other assembly. This is also with the understandingthat the description thereof will be applicable to the other likesimplex assemblies.

As discussed with respect to the first embodiment of the fiber opticconnector assembly 10 of FIGS. 1-19, the simplex assembly 210 may bejoined to another simplex assembly with at least one removable joint pin16 that is coupled to the connectors 14 of the assemblies 210. Also,each carrier 212 includes a hole 218 on a first side 220 and anintegrally molded pin 222 on an opposing second side 224 so that twocarriers 212 may be joined together. Since each carrier 212 includes ahole 218 and a molded pin 222 on opposite, alternating sides, a carrier212 can be joined to another carrier at either side thereof.

As discussed previously, the separability of the fiber optic connectorassemblies 210 provides the advantage of using one or two simplexassemblies, as needed, or being able to swap the assemblies when theposition of the two fiber optic connectors 14 have to be switchedrelative to one another. For example, the position of the two fiberoptic connectors 14 may have to be switched when the fiber opticconnector assembly 210 of the present disclosure is used as an insertwithin a housing such as the housing of a hybrid fiber/copper connectoror a quad connector as described in U.S. patent application entitled“HYBRID FIBER/COPPER CONNECTOR SYSTEM AND METHOD”, filed Nov. 26, 2008,having Ser. No. 12/323,980, the entire disclosure of which has beenincorporated herein by reference.

As discussed in the above-mentioned applications that have beenincorporated herein by reference, if the gender of one of the hybridconnectors or quad connectors needs to be changed, the position of thetwo fiber optic connectors 14 within the housing may need to beswitched. This can be accomplished by separating the two simplex fiberoptic connector assemblies 210 of the present disclosure and swappingtheir positions.

As discussed previously, the simplex fiber optic connector assembly 210may be configured to be joined to any number of like assemblies, eitherremovably or integrally, and terminate any number of fibers. Duplexassemblies are one example.

As in the embodiment discussed previously, although described in U.S.patent application entitled “HYBRID FIBER/COPPER CONNECTOR SYSTEM ANDMETHOD”, filed Nov. 26, 2008, having Ser. No. 12/323,980 as being usablein hybrid or quad connector housings, the fiber optic connector assembly210 can be used as an insert in any type of housing to protect the fiberoptic connector assembly 210 from damage.

It should also be noted that, as in the previous embodiment discussed,the fiber optic connector assembly 210 is not limited to use with a LX.5or BX5-type fiber optic connector within the assembly and may beutilized with other types of fiber optic connectors.

Now referring to FIGS. 20-24, the fiber optic connector assembly 210 issimilar to the fiber optic connector assembly 10 shown in FIGS. 1-19except that, instead of utilizing a heat responsive adhesive element forbonding the field optical fiber and the buffer to the carrier, the fiberoptic connector assembly 210 includes a carrier 212 that is made out ofpolymeric (e.g., a thermoplastic) material, wherein portions of thethermoplastic carrier 212 are configured to melt and assume a flowablecondition and contact the field optic fiber and buffer and provide thebonding. As in the fiber optic connector assembly 10 of FIGS. 1-19, thefiber optic connector assembly 210 includes the fiber optic connector14, the alignment guide 28, and a saddle assembly 226. However, thesaddle assembly 226 does not include the heat responsive adhesiveelement. As discussed, portions of the carrier 212 are configured to bemelted to provide the bonding instead of utilizing a separate heatresponsive adhesive element.

The carrier 212 of the fiber optic connector assembly 210 is shown indetail in FIGS. 40-43. Referring to FIGS. 20-24 and FIGS. 40-43, similarto the carrier 12 of the fiber optic connector assembly 10 of FIGS.1-19, the carrier 212 includes a connector end 234 and a cable end 236,which is oppositely disposed from the connector end 234. In the presentembodiment, the connector end 234 defines a slot 238 for slidablymounting a fiber optic connector 14. As in the previous embodiment, theconnector 14 may be a connector whose further details are described inU.S. Pat. Nos. 5,883,995 and 6,142,676 and U.S. patent application Ser.No. 11/735,267, incorporated herein by reference in their entirety. Theconnector 14 defines a tube 40 adjacent the rear end 42 of the connector14. The tube 40 defines an annular groove 44 disposed on the outersurface of the tube 40. The connector 14 is placed on the carrier 212with the annular groove 44 slidably fitting in the slot 238 of thecarrier 212. Once slidably inserted, the connector 14 may be epoxied tothe carrier 212. It will be understood by those skilled in the art thatthe scope of the present disclosure is not limited to the carrierdefining a slot for mounting the connector and that the connector can bemounted to the carrier in any other suitable manner.

Still referring to FIGS. 20-24 and 40-43, disposed between the connectorend 234 and the cable end 236 of the carrier 212 is a fiber support 248.In the embodiment shown, the fiber support 248 defines a U-shaped guideway 250.

Similar to the carrier 12 of the fiber optic connector assembly 10 ofFIGS. 1-19, a termination region 252 is disposed between the cable end236 of the carrier 212 and the fiber support 248. A factory terminatedfiber that extends from the connector 14 is mechanically spliced to afield fiber that is aligned with the factory fiber in the terminationregion 252.

The termination region 252 of the carrier 212 defines a groove 254 forsupporting the alignment guide 28. The groove 254 is contoured to fitthe outer surface of the alignment guide 28. The termination region 252also defines a guide path 256 that extends from the rear end of thealignment guide 28 (when the alignment guide is in place) to the cableend 236 of the carrier 212. The guide path 256 is configured togenerally align with a crimp tube hole 260 defined at the cable end 236of the carrier 212 and also align with the guide way 250 of the fibersupport 248 of the carrier 212. When the alignment guide 28 ispositioned within the carrier 212, the guide path 256 also aligns withthe throughhole 104 of the alignment guide 28 so that a factoryterminated fiber can be matched up to the field fiber.

The carrier 212 defines right and left vertical walls 263, 265,respectively, extending upwardly adjacent the cable end 236 of thecarrier 212. The right and left vertical walls 263, 265 surround theguide path 256 that extends from the rear end 108 of the alignment guide28 (when the alignment guide is in place) to the cable end 236 of thecarrier 212. As will be discussed in further detail below, the right andleft vertical walls 263, 265 are configured to support the saddleassembly 226 and when thermal energy is applied to the saddle assembly226, the right and the left vertical walls 263, 265 are configured tomelt to bond the field fiber and buffer to the carrier 212.

The carrier 212 further includes a crimp tube 274 integrally molded withthe thermoplastic carrier 212. The crimp tube 274 defines a passagewaythrough which the cleaved field optical fiber is inserted. Strengthmembers/layers (e.g., Kevlar) of a fiber optic cable can be crimped onthe outer surface of the crimp tube 274 for securing the fiber opticcable to the carrier 212.

Referring now to FIGS. 20-24, when the saddle 72 is placed on thecarrier 212, the bottom surface 90 of the saddle 72 makes contact withthe top surfaces 267 of the right and left vertical walls 263, 265. Theright and left vertical walls 263, 265 are received between thedownwardly extending legs 70 of the saddle 72. As in the previousembodiment, the saddle 72 is in thermally conductive contact with aresistor 80 which sits on a top surface 92 of the saddle 72, when thesaddle assembly 226 is assembled.

When thermal energy is applied to the saddle 72 through the resistor 80,the right and left vertical walls 263, 265 that are in contact with thesaddle 72 start to melt. The saddle 72 moves vertically downwardly withrespect to the carrier 212 with the legs 70 of the saddle 72 ridingalong the recesses 268 defined at the sidewalls 264, 266 of the carrier212. The legs 70 of the saddle 72 assist in directing the melting,flowable material toward the center of the carrier 212 into the guidepath 256.

Although in the present disclosure, each carrier 212 is shown to includeits own individual saddle 72, in other embodiments, a single, largersaddle may be used to expand the width of two or more simplex carriers212.

As discussed above, the use of the fiber optic connector assembly 210 ofFIGS. 20-24 is similar to that of the fiber optic connector assembly 10of FIGS. 1-19. In use, with the connector 14 engaged to the carrier 212,the optical fiber affixed in the guide way 250 of the fiber support 248,and the factory fiber end inserted into the throughhole 104 of the base100 of the alignment guide 28, an end of the cleaved field optical fiberis inserted into the passageway of the crimp tube 274 defined at therear of the carrier 212. The end of the cleaved field optical fiber isinserted between the right and left vertical walls 263, 265 of thecarrier 212 and into the throughhole 104 of the base 100 of thealignment guide 28. An index matching gel is disposed between thecleaved end of the cleaved field optical fiber and the end of thefactory optical fiber.

With the cleaved end of the cleaved field optical fiber inserted intothe alignment guide 28, optical radiation is passed through the opticalfibers to assess proper alignment of the fiber end of the factory fiberand the cleaved end of the field fiber through the window 102. Oncealignment is established, to secure the cleaved optical fiber and thebuffer to the fiber optic connector assembly 210, an electrical powersource is connected to the resistor 80. Electrical current is passedthrough the resistor 80 which transfers the heat energy to the thermallyconductive saddle 72. As the thermally conductive saddle 72 transfersthe heat energy to the right and left vertical walls 263, 265 of thecarrier 212, the vertical walls 263, 265 begin to melt and assume aflowable condition. The melting material adheres to the buffer and thecleaved optical fiber and closes the passageway of the crimp tube 274.When the current is interrupted, the melted material solidifies tosecure the buffer and the cleaved optical fiber in its correct positionin alignment with the factory optical fiber.

As discussed above, when the vertical walls 263, 265 first start to meltand flow, the legs 70 of the saddle 72 slide vertically downwardly alongthe recesses 268 defined at the sidewalls 264, 266 of the carrier 212.The legs 70 of the saddle 72 contain the melting material and direct ittoward the guide path 256 of the carrier 212.

As shown in FIGS. 22 and 24 and as discussed with respect to theprevious embodiment of the fiber optic connector assembly 10, thecutaway region 114 of the base 100 of the alignment guide 28 isconfigured to accommodate at least a portion of the saddle 72 as thesaddle 72 moves downwardly relative to the carrier 212. When the meltedportion of the thermoplastic carrier 212 solidifies, the buffer of thefield fiber is sealed to the guide path 256 of the carrier terminationregion 252, the rear end of the base 100 of the alignment guide 28 issealed to the groove 254 in the carrier 212, and the field fiber issealed to the base 100 of the alignment guide 28, securing the entirerear side of the fiber optic termination assembly 210 in correctalignment.

As discussed above, in certain embodiments, the carrier of the fiberoptic connector assembly may be manufactured out of a thermoplasticmaterial such as PEI. The carrier may be manufactured from other typesof polymeric materials. As also discussed previously, by manufacturingthe carrier out of a polymeric material, substantially all of the heatenergy from the resistor 80 is initially transferred to the conductivesaddle 72 rather than the carrier itself A carrier made out of a metalmaterial may act as a heat sink and absorb some of the thermal energyfrom the saddle 72, affecting the heating of the saddle 72, and, thus,affecting the melting of the right and left walls 263, 265. There,however, may be applications in which a metallic carrier is preferred.

It should be noted that, even though a thermoplastic carrier withmeltable portions is utilized, the fiber optic connector assembly maystill include a heat responsive adhesive element that is used incombination with the thermoplastic carrier. Referring now to FIGS.25-29, a third embodiment of a fiber optic connector assembly 310 thatcan be used in terminating at least one optical fiber in the field isshown. The fiber optic connector assembly 310 is similar in constructionand use to the fiber optic connector assembly 210 shown in FIGS. 20-24of the present disclosure, except it further includes a heat responsiveadhesive element 382 that is used in addition to the meltable right andleft vertical walls 263, 265 of a thermoplastic carrier 212.

The fiber optic connector assembly 310 may utilize the same carrier 212that is shown and described with respect to the embodiment of FIGS.20-24. In the fiber optic connector assembly 310 of FIGS. 25-29, thesaddle assembly 326 includes the saddle 72 and the resistor 80 with aheat responsive adhesive element 382 configured to be positioned betweenthe saddle 72 and the meltable vertical walls 263, 265 of the carrier212. In the embodiment shown, the heat responsive element 382 is a gluepellet 383. Although in the depicted embodiment, glue pellet 383 isshown as being generally rectangular, it will be understood by thoseskilled in the art that other shapes for the glue pellet may be used.For example, the glue pellet may or may not include a preformed channel,depending upon the application.

As in the previous embodiment of the fiber optic connector 10 of FIGS.1-19, the glue pellet 383 is in thermally conductive contact with thesaddle 72, which is in thermally conductive contact with the resistor80. The first surface 384 of the glue pellet 383 is in contact with abottom surface 90 of the saddle 72, thereby establishing the thermallyconductive contact between the glue pellet 383 and the saddle 72. Theresistor 80 is in contact with a top surface 92 of the saddle 72,thereby establishing the thermally conductive contact between theresistor 80 and the saddle 72.

Still referring to FIGS. 25-29, the glue pellet 383 is received betweenthe legs 70 of the saddle 72. The legs 70 are configured to slide withinthe recesses 268 defined on the sidewalls 264, 266 of the carrier 212.When thermal energy is applied to the saddle 72 through the resistor 80and both the glue pellet 383 and the right and left vertical walls 263,265 of the carrier 212 melt, the saddle 72 moves vertically downwardlywith respect to the carrier 212 with the legs 70 riding along therecesses 268.

As discussed above, the melting glue 383 and the thermoplastic materialare contained and guided toward the center of the carrier 212 into theguide path 256 by the legs 70 of the saddle 72.

Even though the previous embodiments of the fiber optic connectorassembly were described as including saddle assemblies that utilizedelectrical current through a resistor element 80 to melt thethermoplastic material and/or the glue, it should be noted that othervarious heat application sources may be used. In the above examples, anenergy source that directed electrical energy through a resistor 80 thatis in contact with a metallic saddle 72 was the main heat source. Aselectrical current flowed through the resistor 80, heat was generatedand passed on to the adjacent saddle 72. As discussed above, the saddle72 was strategically placed to melt a designated zone of the plasticcarrier 212 and the thermal glue if desired.

Referring now to FIGS. 30-34, a fourth embodiment of a fiber opticconnector assembly 410 that can be used in terminating at least oneoptical fiber in the field is shown. The fiber optic connector assembly410 is similar in construction and use to the fiber optic connectorassemblies 210, 310 shown in FIGS. 20-29 of the present disclosure,except that it utilizes a different heat source than those embodimentspreviously described.

The fiber optic connector assembly 410 includes essentially all of thefeatures of the fiber optic connector assembly of FIGS. 20-24 except fora resistor 80. In the embodiment shown in FIGS. 30-34, a heat elementsuch as a solder iron may be used to apply heat directly to the metallicsaddle 72. The thermally conductive metallic saddle 72, then, transfersthe heat energy to the vertical walls 263, 265 of the carrier 212 tomelt the vertical walls 263, 265.

Tools such as a solder iron may be run through a timing or travelmechanism to control precisely how long the heat source is allowed tomelt the thermoplastic material. The addition of a time or a travelmechanism can allow the field technician to consistently apply the samemelt parameters continuously over multiple terminations, thus generatingrepeatable process results.

It should be noted that the use of a solder iron in direct contact withthe metallic saddle 72 is simply one example of another heat source thatmight be used in the termination process. Other heat sources such asother heat generating tools may be used. Certain tools such as a solderiron that is used in direct contact with a metallic saddle 72 can allowlow cost heating solutions that would provide the proper meltingoperation.

Referring now to FIGS. 35-39, a fifth embodiment of a fiber opticconnector assembly 510 that can be used in terminating at least oneoptical fiber in the field is shown. The fiber optic connector assembly510 is similar in construction and use to the fiber optic connectorassemblies 210, 310, and 410 shown in FIGS. 20-34 of the presentdisclosure.

The fiber optic connector assembly 510 shown in FIGS. 35-39 is similarto the embodiment shown in FIGS. 30-34 in that it is configured toutilize a heat source that is in direct contact with the metallic saddle72, rather than through a resistor 80. As discussed above, one exampleof such a heat source may be a solder iron that is used to apply heatdirectly to the metallic saddle 72.

The fiber optic connector assembly 510 shown in FIGS. 35-39 is alsosimilar to the embodiment shown in FIGS. 25-29 in that the fiber opticconnector assembly 510 includes a heat responsive adhesive element 382that is used in combination with the thermoplastic carrier 212. Thefiber optic connector assembly 510 is similar in construction and use tothe fiber optic connector assembly 310 shown in FIGS. 25-29 in that itfurther includes a heat responsive adhesive element 382 depicted as aglue 383 that is used in addition to the meltable right and leftvertical walls 263, 265 of a thermoplastic carrier 212.

In the fiber optic connector assembly 510 of FIGS. 35-39, the gluepellet 383 is in thermally conductive contact with the saddle 72. Thefirst surface 384 of the glue pellet 383 is in contact with a bottomsurface 90 of the saddle 72, thereby establishing the thermallyconductive contact between the glue pellet 383 and the saddle 72. Asdiscussed, a heat source such as a solder iron may be used to applythermal energy directly to the saddle 72. The solder iron may or may notbe used with mechanisms such as a timing or a travel mechanism.

Still referring to FIGS. 35-39, the glue pellet 383 is received betweenthe legs 70 of the saddle 72. The legs 70 are configured to slide withinthe recesses 268 defined on the sidewalls 264, 266 of the carrier 212.When thermal energy is applied to the saddle 212 directly through asolder iron and both the glue pellet 383 and the right and left verticalwalls 263, 265 of the carrier 212 melt and assume a flowable condition,the saddle 72 moves vertically downwardly with respect to the carrier212 with the legs 70 riding along the recesses 268. As discussed above,the melting glue 383 and the thermoplastic material are contained andguided toward the center of the carrier 212 into the guide path 256 bythe legs 70 of the saddle 72.

Although all of the fiber optic connector assemblies disclosed hereinhave been described as being used to terminate a field fiber to a fiberoptic connector, it should be noted that all of the aspects and featuresof the fiber optic connector assemblies described herein may be used toprovide a termination assembly that can be used to terminate a firstoptical fiber to a second optical fiber, wherein neither of the opticalfibers are terminated to a connector 14. One example embodiment of sucha termination assembly is described and shown in U.S. patent applicationentitled “FIELD TERMINATION KIT”, filed Apr. 11, 2008, having Ser. No.12/101,366, the entire disclosure of which has been incorporated hereinby reference.

FIGS. 44-73 illustrate different examples of termination assemblies thatare used to terminate a first optical fiber to a second optical fiber,wherein the termination assemblies include features and aspectsdiscussed with respect to the fiber optic connector terminationassemblies 10, 210, 310, 410, 510 discussed herein.

For example, FIGS. 44-48 illustrate an embodiment of a terminationassembly 610 that is used to connect two optical fibers together,wherein the termination assembly 610 includes features similar to thoseof the embodiment shown in FIGS. 20-24, wherein the carrier 612 ismanufactured from a thermoplastic material and includes meltableportions for providing the bonding.

FIGS. 49-53 illustrate another embodiment of a termination assembly 710that is used to connect two optical fibers together, wherein thetermination assembly 710 includes features similar to those of theembodiment shown in FIGS. 25-29, wherein a heat activated adhesiveelement 382 is utilized in addition to a thermoplastic carrier 612 withmeltable portions.

FIGS. 54-58 illustrate another embodiment of a termination assembly 810that is used to connect two optical fibers together, wherein thetermination assembly 810 includes features similar to those of theembodiment shown in FIGS. 30-34, wherein a heat source such as a solderiron may be used to apply heat directly to the saddle 72 rather thanthrough a resistor 80.

FIGS. 59-63 illustrate yet another embodiment of a termination assembly910 that is used to connect two optical fibers together, wherein thetermination assembly 910 includes features similar to those of theembodiment shown in FIGS. 35-39, wherein a heat activated adhesiveelement 382 is used in combination with a thermoplastic carrier 612 andheat is applied through a heating element such as a solder iron directlyto the saddle 72.

FIGS. 64-65 illustrate a carrier 612 that can be used with thetermination assemblies 610, 710, 810, and 910 shown in FIGS. 44-63.FIGS. 66-67 illustrate a carrier 1012 that does not includethermoplastic meltable portions and which can be used in terminationassemblies having features and aspects similar to that shown in FIGS.1-19.

FIGS. 68-73 illustrate an alignment guide 628 that can be used with thetermination assemblies 610, 710, 810, and 910 shown in FIGS. 44-63.

All of the termination assemblies shown in FIGS. 44-73 are similar inconstruction and use to the fiber optic termination assemblies shown inFIGS. 1-43 except that the termination assemblies shown in FIGS. 44-73are used to terminate two optical fibers together, wherein neither ofthe optical fibers are terminated to a fiber optic connector 14.

Referring now to FIGS. 44-73, each of the termination assembliesincludes a carrier 612 having a first end 634 and a second end 636. Atermination region 652 is disposed between the first and second ends634, 636. The termination region 652 defines a cavity 654. The cavity654 is adapted to receive an alignment guide 628 (shown in FIGS. 68-73).The alignment guide 628, as in the previous fiber optic connectortermination assemblies, serves as the location for the termination ofthe optical fibers. The alignment guide 628 includes features similar tothose of the alignment guide 28 of FIGS. 7-19, except that it isconfigured to accommodate saddle assemblies at both ends as shown inFIGS. 68-73.

Similar to the alignment guide 28 shown in FIGS. 7-19, the alignmentguide 628 of FIGS. 68-73 includes a base 700 and an alignment window 102that is separately mounted on the base 700. The base 700 is generallycylindrical in shape and defines a throughhole 704 extending from afirst end 706 to the second end 708. At each end, the base 700 defines aconical portion 709. The conical portions 709 taper from a largerdiameter portion adjacent the ends toward a small diameter portiontoward the center of the base 700. The conical portions 709 areconfigured to facilitate insertion of the optical fibers into the base700.

The alignment guide 628 also includes a cutout portion 712 about halfwayalong the length of the base 700. The cutout 712 accommodates the window102 (see FIGS. 7, 8, 10, and 17-19) that is placed on the base 700. Thecutout 712 is configured to expose and communicate with the throughhole704 extending from the first end 706 to the second end 708 of the base700.

As discussed, the base 700 also includes a cutaway region 714 adjacentboth the first and the second end. Each cutaway region 714 is configuredto accommodate a portion of the saddle 72 when the saddle 72 movesvertically downwardly, either due to the melting of the glue 383, themelting of the vertical walls 663, 665 of the thermoplastic carrier 612,or both. When the saddle 72 comes to rest, the bottom surface 90 of thesaddle 72 may rest on the cutaway region 714 on each end of the base700.

The termination region 652 of the carrier 612 defines a first guide path656 that extends from the first end 706 of the alignment guide 628 (whenthe alignment guide is in place) to a first cable end 636 of the carrier612 and a second guide path 657 that extends from the second end 708 ofthe alignment guide 628 (when the alignment guide is in place) to asecond cable end 637 of the carrier 612.

In the carriers 612 used with the embodiments shown in FIGS. 44-73,crimp tubes 674 are engaged with both the first and second ends 636, 637of the carrier 612. The crimp tubes 674 define passageways through whichthe optical fibers are inserted at both ends of the carrier 612.

As shown in FIGS. 44-73, a saddle assembly is positioned adjacent eachof the first and second cable ends 636, 637 of the carrier 612. Each ofthe saddle assemblies may include features similar to and are used in amanner similar to those embodiments described with respect to FIGS.1-43.

For example, in the embodiment of the termination assembly 610 shown inFIGS. 44-48, the carrier 612 is manufactured from a thermoplasticmaterial and includes meltable portions for providing the bonding andthe saddle assembly includes a resistor 80.

In the embodiment of the termination assembly 710 of FIGS. 49-53, a heatactivated adhesive element 382 is utilized in addition to athermoplastic carrier 612 with meltable portions.

In the embodiment of the termination assembly 810 of FIGS. 54-58, thesaddle assembly does not include a resistor 80 and a heat source such asa solder iron may be used to apply heat directly to the saddle 72.

In the embodiment of the termination assembly 910 of FIGS. 59-63, a heatactivated adhesive element 382 is used in combination with athermoplastic carrier 612 and heat is applied through a heating elementsuch as a solder iron directly to the saddle 72, rather than through aresistor 80.

Various modifications and alterations of this disclosure will becomeapparent to those skilled in the art without departing from the scopeand spirit of this disclosure, and it should be understood that theinventive features are not to be unduly limited to the illustrativeembodiments set forth herein.

The invention claimed is:
 1. A fiber optic connector assemblycomprising: a fiber optic connector having a first mating end and asecond end; a first optical fiber terminated to the fiber opticconnector, the first optical fiber defining a first end adjacent themating end for optical connection to a second fiber optic connector, thefirst optical fiber defining a second end protruding out of the secondend of the fiber optic connector; a polymeric carrier having a connectorend engaged with the fiber optic connector and an oppositely disposedcable end, the polymeric carrier including a heat activated meltableportion adjacent the cable end; and an alignment structure disposed onthe carrier, the alignment structure including a first end and a secondend and a throughhole extending from the first end to the second end,the first end of the alignment structure configured to receive thesecond end of the first optical fiber and the second end of thealignment structure configured to receive an end of a second opticalfiber entering the cable end of the carrier; wherein the heat activatedportion of the polymeric carrier is configured to melt and assume aflowable condition when exposed to a predetermined amount of heat andresolidify when the heat is removed to bond the second optical fiber tothe carrier; wherein the carrier defines a guide path adjacent the cableend for receiving the end of the second optical fiber entering the cableend, the heat activated meltable portion of the carrier including firstand second parallel vertical walls surrounding the guide path.
 2. Afiber optic connector assembly according to claim 1, further comprisinga heat activated adhesive element positioned adjacent the meltableportion of the polymeric carrier, the heat activated adhesive elementalso configured to melt and assume a flowable condition when exposed toa predetermined amount of heat and resolidify when the heat is removedfor bonding the second optical fiber to the carrier.
 3. A fiber opticconnector assembly according to claim 2, further comprising a resistorin thermal conductive contact with a conductive element positioned onthe heat activated adhesive element, the conductive element configuredto transfer heat from the resistor to the heat activated adhesiveelement and the meltable portion of the polymeric carrier, theconductive element configured to move with respect to the carrier whenthe heat activated adhesive element and the meltable portion of thecarrier melt and assume a flowable condition.
 4. A fiber optic assemblyaccording to claim 1, wherein the alignment structure includes a cutawayportion extending generally perpendicularly to and communicating withthe throughhole, the first optical fiber terminated to the fiber opticconnector being positioned within at least a portion of the throughholewith the second end of the first optical fiber located within thecutaway portion of the alignment structure, wherein a window is disposedwithin the cutaway portion of the alignment structure over the secondend of the first optic fiber, the window configured for visuallyinspecting an alignment of the second end of the first optical fiberwith the end of the second optical fiber entering the cable end of thecarrier.
 5. A fiber optic connector assembly according to claim 4,wherein the window is made out of pyrex material.
 6. A fiber opticconnector assembly according to claim 1, further comprising a resistorin thermal conductive contact with a conductive element positioned onthe meltable portion of the carrier, the conductive element configuredto transfer heat from the resistor to the meltable portion of thepolymeric carrier, the conductive element configured to move withrespect to the carrier when the meltable portion of the carrier meltsand assumes a flowable condition.
 7. A fiber optic connector assemblyaccording to claim 1, wherein the alignment structure is generallycylindrical in shape.
 8. A fiber optic connector assembly according toclaim 1, wherein the alignment structure includes a conical portion onat least the first end and the second end of the alignment structure. 9.A method of terminating a factory optical fiber to a field optical fibercomprising: terminating the factory optical fiber to the fiber opticconnector with an end of the factory optical fiber protruding from thefiber optic connector; providing a polymeric carrier having a connectorend engaged with the fiber optic connector and an oppositely disposedcable end, the polymeric carrier including a heat activated meltableportion adjacent the cable end; providing an alignment structure on thepolymeric carrier, the alignment structure including a first end and asecond end and a throughhole extending from the first end to the secondend; inserting the factory optical fiber protruding from the fiber opticconnector into the throughhole of the alignment structure from the firstend of the alignment structure; inserting the field optical fiber intothe throughhole of the alignment structure from the second end of thealignment structure; aligning an end of the field optical fiber with theend of the factory optical fiber within the throughhole of the alignmentstructure; providing heat to the heat activated meltable portion of thepolymeric carrier to melt and bring the carrier to a flowable conditionfor securing the factory optical fiber to the field optical fiber; andproviding a heat activated adhesive element adjacent the meltableportion of the polymeric carrier, the heat activated adhesive elementconfigured to melt and assume a flowable condition when exposed to apredetermined amount of heat and resolidify when the heat is removed forbonding the factory optical fiber to the field optical fiber.
 10. Amethod according to claim 9, further comprising removing the heat fromthe meltable portion of the carrier to allow the meltable portion toresolidify to secure the factory optical fiber to the field opticalfiber.
 11. A method according to claim 9, wherein the alignmentstructure includes a cutaway portion extending generally perpendicularlyto and communicating with the throughhole, the method further comprisinginserting the factory optical fiber protruding from the fiber opticconnector into the throughhole of the alignment structure from the firstend with the end of the factory optical fiber positioned within thecutaway portion of the alignment structure and providing a window withinthe cutaway portion of the alignment structure over the ends of thefactory and field optical fibers for visually inspecting an alignment ofthe optical fibers.
 12. A method according to claim 11, wherein thewindow is made out of pyrex material.
 13. A method according to claim 9,further comprising providing a resistor in thermal conductive contactwith a conductive element positioned on the heat activated adhesiveelement, the conductive element configured to transfer heat from theresistor to the heat activated adhesive element and the meltable portionof the polymeric carrier.
 14. A method according to claim 9, furthercomprising providing a resistor in thermal conductive contact with aconductive element positioned on the meltable portion of the carrier,the conductive element configured to transfer heat from the resistor tothe meltable portion of the polymeric carrier.
 15. A method according toclaim 9, wherein the alignment structure is generally cylindrical inshape and includes a conical portion on at least the first end and thesecond end of the alignment structure.
 16. A fiber optic connectorassembly comprising: a fiber optic connector having a first mating endand a second end; a first optical fiber terminated to the fiber opticconnector, the first optical fiber defining a first end adjacent themating end for optical connection to a second fiber optic connector, thefirst optical fiber defining a second end protruding out of the secondend of the fiber optic connector; a polymeric carrier having a connectorend engaged with the fiber optic connector and an oppositely disposedcable end, the polymeric carrier including a heat activated meltableportion adjacent the cable end; and an alignment structure disposed onthe carrier, the alignment structure including a first end and a secondend and a throughhole extending from the first end to the second end,the first end of the alignment structure configured to receive thesecond end of the first optical fiber and the second end of thealignment structure configured to receive an end of a second opticalfiber entering the cable end of the carrier; wherein the heat activatedportion of the polymeric carrier is configured to melt and assume aflowable condition when exposed to a predetermined amount of heat andresolidify when the heat is removed to bond the second optical fiber tothe carrier; wherein a heat activated adhesive element is positionedadjacent the meltable portion of the polymeric carrier, the heatactivated adhesive element also configured to melt and assume a flowablecondition when exposed to a predetermined amount of heat and resolidifywhen the heat is removed for bonding the second optical fiber to thecarrier.
 17. A fiber optic connector assembly according to claim 16,further comprising a resistor in thermal conductive contact with aconductive element positioned on the heat activated adhesive element,the conductive element configured to transfer heat from the resistor tothe heat activated adhesive element and the meltable portion of thepolymeric carrier, the conductive element configured to move withrespect to the carrier when the heat activated adhesive element and themeltable portion of the carrier melt and assume a flowable condition.